Apparatus for dyeing pile carpets



Jan. 4, 1966 R. J. LINCOLN 3,226,962

APPARATUS FOR DYEING FILE CARPETS Filed March 25, 1964 INVENTOR. ROBERTJ. LINCOLN ikww ATTOR United States Patent 3,226,962 APPARATUS FORDYEING PILE CARPETS Robert J. Lincoln, Chester, Va., assignor toMonsanto Company, a corporation of Delaware Filed Mar. 25, 1964, Ser.No. 354,717 3 Claims. (Cl. 68-177) This invention relates to dyeing and,more specifically, to an apparatus for piece dyeing carpets, rugs andthe like.

In the manufacturing of carpets and especially in the manufacture ofcarpets having the piles or tufts which are comprised of syntheticfibers, certain problems are encountered when the dye is appliedthereto. When the carpets are subjected to the high temperature of a dyebath, the filaments comprising the pile have a tendency to wilt and laydown. If the temperature of the dye bath is kept relatively low, the dyereceptivity of the synthetic filaments is greatly reduced therebylimiting the effectiveness of the dyeing operation and reducing theaesthetic value of the carpet. The pile may be dyed before being tuftedinto the.carpet scrim, however, such a practice limits the flexibilitywith which the dye may be applied to the carpet for once dyed, it cannotbe re-dyed by the normal process. The main problem in piece dyeingcenters around keeping the pile erect throughout the dyeing cycle forthe synthetic piles characteristically retain the position last obtainedwhen cooled from a heated state. When piece dyeing carpet and the likein a conventional dye vat, the ends of a length of carpet are sewntogether after it has been laid over and around advancing rollers. Aportion of the carpet hangs over the rollers and is emersed in a dyeliquor which partially fills the dye vat. The carpet is moved by theadvancing roller through the dyeing liquor in a continuous belt fashion.As a segment of carpet emerges from the dye bath, the liquor due togravity runs down the surface thereof and back into 5 the dye bath.Since the liquor is hot and since the othersing operation is repeatedseveral times, the carpet pile tend to slant in the direction of theliquor flow and upon cooling, remains in that position. It is to thisdisadvantage that the attention of this application will be directed.Therefore, an object of this invention is to provide an apparatus fordyeing carpet which leaves the pile in an erected position.

Another object of this invention is to provide an apparatus for piecedyeing carpet by completely submerging the same.

A further object of this invention is to provide a carpet the pile ofwhich retains resilience and erectness after being dyed.

Other objects and advantages of this invention will become apparent whenthe following detailed description is read in conjunction with theappended drawings, specifications, and claims. The preferred embodimentof this invention will now be described with reference to theaccompanying drawings.

The figure is a front elevational, sectional view of the apparatus usedto perform this process showing the carpet draped around the rollerswith the excess extending into the lower portions of the dye vat andcollecting there.

In general, this invention consists of a tank or fluid receptacle whichreceives a positively driven roller that is horizontally mounted forrotation about its axis. The driven roller is provided with a knurledsurface which frictionally engages carpet backing or scrim therebyaiding in the movement of the carpet through its orbital path. Thecarpet is laid over the driven roller, around other idler rollers andthe ends thereof are sutured thereby forming an endless belt. Theremainder of the carpet is allowed to drape in the bottom of the fluidreceptacle.

Dyeing liquor is allowed to fill the fluid receptacle thereby coveringthe cloth or carpet completely. In opera tion, the driven roller ispowered by any conventional means and its knurled surface frictionallyengages the carpet backing and advances the same. The carpet pile standserect and is not forced down by the action of advancing rollers or theweight of gravitationally induced dyeing liquor. The carpet pile onlycomes in contact with the dye liquor. The carpet is continuously movedthrough the dye bath thereby insuring proper dyeing for if the dyeingliquor does not properly circulate around the filaments comprising thepile, streaks are left therein. After the piled carpet has completed itsdyeing cycle, the dye liquor is partially drained from the dye vat, thestitch used to form the suture is severed and the carpet is removed fromthe dye vat and allowed to dry. Once the carpet is removed from theheat, the filaments comprising the pile become hard again and regaintheir former bulkiness and resilience and since the pile was not masheddown during the dyeing cycle, they stand erect for the filaments remainin their precooled position.

This invention is illustrated in connection with the accompanyingdrawings in which the figures are illustrative of the preferredembodiment of the invention. It is to be understood that this inventionis applicable to other fabrics than that generally described.

A dye vat or fluid containing receptacle It is mounted on legs 11 andserves to receive a dye liquor 12. The dye vat 10 is of openconstruction and has an arcuated bottom 13 although the particulardesign thereof is of little importance. The dye liquor 12 enters the dyevat 10 through a supply pipe 14 which is connected to a source. Afterthe dye liquor 12 has been used, it may be recycled or dumped into awaste line through waste exhaust line 15. It is also contemplated thatthe supply pipe 14 and the exhaust line 15 may cooperate to continuouslycirculate the dyeing liquor 12 during the dyeing period for the betterthe circulation the more uniformly the carpet is dyed.

Frame 16 is rigidly secured to fluid receptacle 10 by means of a nut andbolt arrangement 17. The frame 16 is comprised of connecting beams 18and 19 and support beam 20. Connecting beams 18 and 19 join at each endof supporting beam 20, thereby positioning it in dye vat 10. Supportingbeam 20 indirectly receives and positions all of the rollers used toadvance a carpet 25 along its path. Bearings 21 are rigidly mounted onsupporting beam 20 and serve to receive an axle 22 which is journaledtherein. Axle 22 comprises a part of advancing roller 23 therebyadapting the same for rotation. about its axis. This axle receives arotating force from a chain and sprocket arrangement 43; however, it isto be understood that the advancing roller 23 may be put in motion byany torque conveying mechanism with equal effectiveness. Advancingroller 23 has a knurled outer surface 24 for catching and advancing thecarpet 25; this surface may be provided with barbs for facilitating themovement thereof. Idler bearings 26 and 27 are secured to seats 31 and32, respectively, which extend from frame 20; also, idler bearings 26and 27 serve to receive axles 33 and 34, respectively, which arejournaled therein. Idler rollers 35 and 36 are rigidly received by axles33 and 34, respectively, and are adapted to reduce friction between thecarpet 25 and the path through which it travels. Also securely mountedon the frame 20 are guiding and aligning bars 37 which extend upwardlyand downwardly therefrom. These bars keep the carpet 25 from walking otfof the edge of the rollers and becoming entangled therein. A plate 38 isattached to the upper ends of guide bars 37, provides a surface acrosswhich the carpet 25 may slide, and guides the carpet 25 from idlerroller 35 to advancing roller 23. The bars 37 in cooperation with theplate 38 and the various rollers also function to provide a path throughwhich the carpet 25 travels.

It is obvious that a long length of carpet may be dyed at one time forWhile a portion of the carpet 25 is drawn relatively taut between idlerroller 35 and advancing roller 23, the rest may be allowed to drape inthe bottom of the dye vat 10.

Many different embodiments of this invention may be made Withoutdeparting from the scope and spirit thereof. It is contemplated thatmany combinations of rollers may be used in moving the carpet along itspath. Therefore, it is to be und-erstood that this invention is not tobe limited to the specific embodiment shown and described herein, exceptas defined in the appended claims.

What is claimed is:

1. An apparatus for dyeing a carpet comprising:

(a) a dye vat, said dye vat being adapted to receive a dyeing liquor,

(b) a structural frame being mounted on and being securely attached tosaid dye vat and extending below the surface or" said dyeing liquor,

(c) an advancing roller being rotatably mounted on said frame, saidadvancing roller having a knurled surface being adapted to frictionallyengage said carpet thereby adapting said advancing roller for advancingsaid carpet along a path,

(d) an idler roller being rotatably mounted on said frame and disposedfrom said advancing roller, said idler roller cooperating with saidadvancing roller to continuously move said carpet through said dyeingliquor, said carpet being completely submerged therein,

(e) aligning bars being rigidly secured to said structural frame andextending above and below said structural frame, said aligning barsbeing adapted to position said canpet on said rollers, and

(f) a plate being mounted on the upper ends of said aligning bars andbeing adapted to guide said carpet from said idler rollers to saidadvancing roller.

2. An apparatus for dyeing a carpet comprising (a) a dye vat, said dyevat being adapted to receive a dyeing liquor, I

(b) a structural frame being mounted on and being securely attached tosaid dye vat and extending below the surface of said dyeing liquor,

(c) an advancing roller being rotatably mounted on said frame, saidadvancing roller having a knurled surface being adapted to frictionallyengage said carpet thereby adapting said advancing'roller foradvancingsaid carpet along a path,

((1) an idler roller being rotatably mounted on said frame and disposedfrom said advancing roller, said idler roller cooperating with saidadvancing roller to continuously move said carpet through said dyeingliquor, said carpet being completely submerged therein, and

(e) aligning bars being rigidly secured to said structural frame andextending above and below said structural frame, said aligning barsbeing adapted to position said carpet on said rollers.

3. An apparatus for dyeing a carpet comprising (a) a dye vat, said dyevat being adapted to receive a dyeing liquor,

(b) a structural frame being mounted on and being securely attached tosaid dye vat and extending below the surface of said dyeing liquor,

(c) an advancing roller being rotatably mounted on said frame, saidadvancing roller having a knurled surface being adapted to frictionallyengage said carpet thereby adapting said advancing roller (for advancingsaid carpet along the path,

((1) an idler roller being rotatably mounted on said frame and disposedfrom said advancing roller, said idler roller cooperating with saidadvancing roller to continuously move said carpet through said dyeingliquor, said carpet being completely submerged therein, and

(e) a plate being mounted on said structural frame and being adapted toguide said carpet from said idler rollers to said advancing roller.

References (Jited by the Examiner UNITED STATES PATENTS 1,006,471 10/1911 Eicken 68-180 1,096,997 5/1914 Brook 8-151 1,097,967 5/1914Craddock 68-155 1,125,691 1/1915 Just 68-155 1,608,372 11/1926 Borggrave68-43 2,199,233 4/1940 Williams 68-20 X 2,320,891 6/1943 Ryder 68-1763,013,422 12/1961 Amidon 68-177 X WALTER A. SCHEEL, Primary Examiner.

I. BUNEVICH, Examiner.

1. AN APPARATUS FOR DYEING A CARPET COMPRISING: (A) A DYE VAT, SAID DYEVAT BEING ADAPTED TO RECEIVE A DYEING LIQUOR, (B) A STRUCTURAL FRAMEBEING MOUNTED ON AND BEING SECURELY ATTACHED TO SAID DYE VAT ANDEXTENDING BELOW THE SURFACE OF SAID DYEING LIQUOR, (C) AN ADVANCINGROLLER BEING ROTATABLY MOUNTED ON SAID FRAME, SAID ADVANCING ROLLERHAVING A KNURLED SURFACE BEING ADAPTED TO FRICTIONALLY ENGAGE SAIDCARPET THEREBY ADAPTING SAID ADVANCING ROLLER FOR ADVANCING SAID CARPETALONG A PATH, (D) AN IDLER ROLLER BEING ROTATABLY MOUNTED ON SAID FRAMEAND DISPOSED FROM SAID ADVANCING ROLLER, SAID IDLER ROLLER COOPERATINGWITH SAID ADVANCING ROLLER TO CONTINUOUSLY MOVE SAID CARPET THROUGH SAIDDYEING LIQUOR, SAID CARPET BEING COMPLETELY SUBMERGED THEREIN, (E)ALIGNING BARS BEING RIGIDLY SECURED TO SAID STRUCTURAL FRAME ANDEXTENDING ABOVE AND BELOW SAID STRUCTURAL FRAME, SAID ALIGNING BARSBEING ADAPTED TO POSITION SAID CARPET ON SAID ROLLERS, AND (F) A PLATEBEING MOUNTED ON THE UPPER ENDS OF SAID ALIGNING BARS AND BEING ADAPTEDTO GUIDE SAID CARPET FROM SAID IDLER ROLLERS TO SAID ADVANCING ROLLER.